Radiopaque foam

Abstract

Embodiments are directed to a radiopaque foam used to repair composite structures. A method for creating the radiopaque foam comprises providing first and second resin components that are radiolucent to x-ray imaging. A barium sulfate component is combined with the second resin component. After combining the barium sulfate component and the second resin component, the first resin component and the second resin component are mixed to create a pourable foam. An amount of barium sulfate combined with the second resin component is sufficient to render the pourable foam radiopaque to x-ray imaging.

What is claimed is: 
     
         1 . A method for creating a radiopaque foam, comprising:
 providing a first resin component that is radiolucent to x-ray imaging;   providing a second resin component that is radiolucent to x-ray imaging;   combining a barium sulfate component with the second resin component; and   after combining the barium sulfate component and the second resin component, mixing the first resin component and the second resin component to create a pourable foam, wherein an amount of barium sulfate combined with the second resin component is sufficient to render the pourable foam radiopaque to x-ray imaging.   
     
     
         2 . The method of  claim 1 , wherein a proportion of the barium sulfate component is 8 grams of barium sulfate to 50 grams of pourable foam. 
     
     
         3 . The method of  claim 1 , wherein the barium sulfate component comprises at least 16% of the pourable foam. 
     
     
         4 . The method of  claim 1 , further comprising:
 depositing the pourable foam in a void space in a composite component;   allowing the pourable foam to cure in the void space; and   creating an x-ray image of the composite component after the pourable foam has been deposited in the void space.   
     
     
         5 . The method of  claim 4 , wherein the composite component is a component of an aircraft rotor, wing, or fuselage. 
     
     
         6 . A method of repairing a composite structure, comprising:
 providing an assembled composite structure comprising a substantially rigid outer component, wherein the composite structure comprises a void space at least partially bounded by the outer component;   inserting a pourable foam into the void space while the foam is in a substantially unexpanded state, wherein the pourable foam comprises a two-part resin mixture having a barium sulfate additive; and   after inserting the pourable foam, performing a nondestructive evaluation of the composite structure using x-rays.   
     
     
         7 . The method of  claim 6 , further comprising:
 forming an injection hole through the outer component to provide a path between the void space and space external to the composite structure; and   wherein inserting the pourable foam comprises injecting the foam into the void space through the injection hole.   
     
     
         8 . The method of  claim 6 , wherein the composite structure comprises a rotor blade. 
     
     
         9 . The method of  claim 8 , wherein the void space is disposed between a spar of the rotor blade and a honeycomb structure of the rotor blade. 
     
     
         10 . The method of  claim 8 , wherein the outer component comprises a skin of the rotor blade. 
     
     
         11 . The method of  claim 6 , further comprising:
 prior to forming the injection hole, performing a nondestructive evaluation of the composite structure to identify the void space.   
     
     
         12 . The method of  claim 11 , wherein the nondestructive evaluation comprises x-ray imaging of the composite structure. 
     
     
         13 . The method of  claim 12 , further comprising:
 capturing an image of x-rays passed through the composite component before injecting the pourable foam.   
     
     
         14 . The method of  claim 6 , further comprising:
 capturing an image of x-rays passed through the composite component after the pourable foam is injected and expanded.   
     
     
         15 . A method of repairing a composite structure, comprising:
 creating a two-part adhesive by mixing a barium sulfate component with a first adhesive part and then combining the first adhesive part with a second adhesive part;   providing an assembled composite structure having an abnormality;   preparing the area of the abnormality for repair by creating a repair surface;   applying the two-part adhesive between the repair surface and a repair material; and   performing a nondestructive evaluation of the composite structure using x-rays.   
     
     
         16 . The method of  claim 15 , wherein preparing the repair surface comprises removing defective material, and wherein the repair material substantially replaces the defective material. 
     
     
         17 . The method of  claim 15 , wherein an amount of the barium sulfate component mixed with first adhesive part is sufficient to render the two-part adhesive radiopaque to x-ray imaging. 
     
     
         18 . The method of  claim 17 , wherein a proportion of the barium sulfate component is 8 grams of barium sulfate to 50 grams of the two-part adhesive. 
     
     
         19 . The method of  claim 17 , wherein the barium sulfate component comprises 16% of the two-part adhesive. 
     
     
         20 . The method of  claim 15 , wherein the composite structure comprises a rotor blade.